Gravel pack joint

ABSTRACT

A gravel pack joint includes a unitary tubular defining a thickness bounded by an outside surface and an inside surface and having an end configured for interconnection with another member. An opening extending from the outside surface through the tubular to the inside surface. A passageway defined within the thickness of the tubular; and a port extending from the outside surface of the tubular to intersect the passageway but not extending to the inside surface of the tubular.

BACKGROUND

In the downhole exploration and recovery industry it is often necessary to control the ingress of sand and similar particulates to produced fluids. Excluding such unwanted particulates before they enter well tubulars is advantageous both because of the reduction in erosion normally caused by conveying a particulate laden fluid and because by leaving the particulates in the hole, there is less solid waste to dispose of later in the process. Gravel packs function well for these purposes as well as helping to maintain borehole integrity by reducing the chance of cave-ins.

Gravel pack configurations rely upon the ability to deliver a slurry laden fluid to an annular space about a tubing string and then dehydrating the slurry to leave behind the sand that forms the gravel pack. While methods exist to produce effective gravel packs, the industry is always striving to improve packs by reducing unpacked areas and to reduce costs involved in gravel packing equipment.

SUMMARY

A gravel pack joint includes a unitary tubular defining a thickness bounded by an outside surface and an inside surface and having an end configured for interconnection with another member; an opening extending from the outside surface through the tubular to the inside surface; a passageway defined within the thickness of the tubular; and a port extending from the outside surface of the tubular to intersect the passageway but not extending to the inside surface of the tubular.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 is a perspective illustration of two gravel pack joints as disclosed herein;

FIG. 2 is a perspective view of the same two joints from FIG. 1 but separated to illustrate the interconnection between the two joints and with screen removed;

FIG. 3 is a cross sectional view of FIG. 1 taken axially along the Figure; and

FIG. 4 is a perspective end view of one of the joints of FIG. 1.

DETAILED DESCRIPTION

Referring to FIG. 1, two gravel pack joints 10 are illustrated adjoined illustrating that while one joint may be employed alone, any number of joints 10 may be strung together to form a longer gravel pack interval. FIG. 2 illustrates the same two joints separated from one another to illustrate one embodiment of a connection therebetween. FIG. 2 also illustrated one of the screens 12 exploded from one of the joints 10. These gravel pack joints in one iteration are a part of a tubular string 11 of a downhole production system.

Each of the gravel pack joints 10 is configured in one embodiment as a unitary tubular composed of metal or composite material (traditional or additive manufacturing) defining a thickness bounded by an outside surface 14 and an inside surface 16 and having an end 18 configured for interconnection with another member. The ends 18 and 20 may be configured as a threaded connection, a snap ring connection, a collet type connection, stab in connection utilizing any of the foregoing connection paradigms capable of non-rotating insertion, quick connection as disclosed in U.S. Pat. No. 9,046,204 incorporated herein by reference, etc. Connections may be to other joints of the gravel pack or to other points of the tubular string of the downhole production system. Threaded connections may be configured as wicker threads 22 (for clarity, 22 a for male threads and 22 b for female threads), helical threads, etc. The end illustrated and identified with numeral 18 is a female configuration but a male configuration is illustrated at the opposing end of joint 10. Ends 18 and 20 are complementary as illustrated but this is not required. It is required that one end of one joint be complementary to the next joint 10 with which it is intended to engage or must be configurable to make the same complementary. For example, both ends of joint 10 could be configured with end 18 and then a short connection sub (not shown but being configured as end 20 and its mirror image where the mirror plane is located at an edge 24 of the joint 10) could function as the engagement nose illustrated at 20. In the wicker connection embodiment, it is noted that the joints 10 can be assemblies without need for torque as the connections are stab in connections only. In embodiments, additional fasteners may be added to ensure the joints 10 stay connected such as fasteners 29.

Each joint 10 includes an opening 26 (one or more) extending from the outside surface 14 through the tubular to the inside surface 16. This or these openings penetrate the entire thickness of the joint 10 to permit fluid communication between an inside of the joint 10 and an annulus environment outside of the joint 10. In use, particulate laden fluid supplied to the annulus will be dehydrated through opening(s) 26. The opening(s) 26 in one embodiment are orthogonally configured relative to the axis of the joint 10. These openings 26 are a return for the slurry used for gravel packing.

The supply of the slurry for the gravel packing is through one or more passageways 28 defined within the thickness of the tubular. These passageways 28 are segregated from the central flow area of the joint 10. They are however open to the annulus through one or more ports 30 that extend from the outside surface 14 to intersect the passageways 28 but not to the inside surface 14 of the joint 10. Accordingly, slurry flowing through the passageways 28 will move into the annulus while traversing the passageway 28. In an embodiment, the ports 30 are angled in a direction along the axis of the joint 10 as illustrated.

Passageways 28 in subsequent joints 10 need not be aligned during assembly due to provision of a recess 32. The recess is in one embodiment as shown an annular structure existing entirely within the thickness of the joint 10. This means that fluid within the recess is segregated from the central flow bore of the joint 10 and will supply the passageways in the next subsequent joint 10 regardless of alignment of the passageways 28 in subsequent joints.

Finally and as best viewed in FIGS. 3 and 4, a screen support 36 is configured as a part of the joint 10. The configuration facilitates the insertion of a screen 12 through one end (the end 20 as shown) into the inside of the joint 10 until the screen is supported on the screen support 36. Then the unsupported end of the screen will become supported by the screen support of the next adjacent joint 10 as seen in FIG. 3. It is intended that screen 12 be understood to be any type of conventional screen material dimensioned to be deposited in place at an inside surface of the joint 10.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1

A gravel pack joint comprising: a unitary tubular defining a thickness bounded by an outside surface and an inside surface and having an end configured for interconnection with another member; an opening extending from the outside surface through the tubular to the inside surface; a passageway defined within the thickness of the tubular; and a port extending from the outside surface of the tubular to intersect the passageway but not extending to the inside surface of the tubular.

Embodiment 2

The gravel pack joint of embodiment 1 wherein the opening is a plurality of openings.

Embodiment 3

The gravel pack joint of embodiment 1 where in the port is a plurality of ports.

Embodiment 4

The gravel pack joint of embodiment 1 wherein the passageway is a plurality of passageways, at least two of the plurality of passageways having intersecting ports.

Embodiment 5

The gravel pack joint of embodiment 1 further comprising a recess defined within the thickness of the tubular and intersecting the passageway.

Embodiment 6

The gravel pack joint of embodiment 5 wherein the passageway is a plurality of passageways, each of which is intersected by the recess.

Embodiment 7

The gravel pack joint of embodiment 1 wherein the port is angled.

Embodiment 8

The gravel pack joint of embodiment 7 wherein the angle is along the axial direction of the joint.

Embodiment 9

The gravel pack joint of embodiment 1 wherein the end includes threads.

Embodiment 10

The gravel pack joint of embodiment 9 wherein the threads are helical.

Embodiment 11

The gravel pack joint of embodiment 9 wherein the threads are wicker threads.

Embodiment 12

The gravel pack joint of embodiment 1 wherein the end further includes fasteners.

Embodiment 13

The gravel pack joint of embodiment 12 wherein the fasteners are threaded fasteners orthogonally arranged.

Embodiment 14

The gravel pack joint of embodiment 1 wherein another end includes an engagement nose.

Embodiment 15

The gravel pack joint of embodiment 14 wherein the engagement nose is of a smaller outside diameter than the tubular.

Embodiment 16

The gravel pack joint of embodiment 1 wherein the opening is orthogonal to the tubular.

Embodiment 17

The gravel pack joint of embodiment 1 wherein the tubular is of composite construction.

Embodiment 18

The gravel pack joint of embodiment 1 further including a screen disposed adjacent the inside surface of the tubular.

Embodiment 19

A downhole production system comprising: a tubular string; and a gravel pack joint of embodiment 1.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).

The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. 

1. A gravel pack joint comprising: a unitary tubular defining a thickness bounded by an outside surface and an inside surface and having an end configured for interconnection with another member; an opening extending from the outside surface through the tubular to the inside surface; a passageway defined within the thickness of the tubular; and a port extending from the outside surface of the tubular to intersect the passageway but not extending to the inside surface of the tubular.
 2. The gravel pack joint as claimed in claim 1 wherein the opening is a plurality of openings.
 3. The gravel pack joint as claimed in claim 1 where in the port is a plurality of ports.
 4. The gravel pack joint as claimed in claim 1 wherein the passageway is a plurality of passageways, at least two of the plurality of passageways having intersecting ports.
 5. The gravel pack joint as claimed in claim 1 further comprising a recess defined within the thickness of the tubular and intersecting the passageway.
 6. The gravel pack joint as claimed in claim 5 wherein the passageway is a plurality of passageways, each of which is intersected by the recess.
 7. The gravel pack joint as claimed in claim 1 wherein the port is angled.
 8. The gravel pack joint as claimed in claim 7 wherein the angle is along the axial direction of the joint.
 9. The gravel pack joint as claimed in claim 1 wherein the end includes threads.
 10. The gravel pack joint as claimed in claim 9 wherein the threads are helical.
 11. The gravel pack joint as claimed in claim 9 wherein the threads are wicker threads.
 12. The gravel pack joint as claimed in claim 1 wherein the end further includes fasteners.
 13. The gravel pack joint as claimed in claim 12 wherein the fasteners are threaded fasteners orthogonally arranged.
 14. The gravel pack joint as claimed in claim 1 wherein another end includes an engagement nose.
 15. The gravel pack joint as claimed in claim 14 wherein the engagement nose is of a smaller outside diameter than the tubular.
 16. The gravel pack joint as claimed in claim 1 wherein the opening is orthogonal to the tubular.
 17. The gravel pack joint as claimed in claim 1 wherein the tubular is of composite construction.
 18. The gravel pack joint as claimed in claim 1 further including a screen disposed adjacent the inside surface of the tubular.
 19. A downhole production system comprising: a tubular string; and a gravel pack joint as claimed in claim
 1. 